Multi zone cementitious product and method

Abstract

A multi-zone cementitious product, which includes a base zone made of a first cementitious material composition and forming a portion of the product. At least one facing zone is adjacent to and bonded to the base zone, the facing zone made of a second cementitious material composition and forming at least one exterior face of said product which is visible when the product is installed. A disrupted boundary layer is between the facing zone and the base zone, and includes material from both the facing zone and the base zone. The disrupted boundary layer bonds the facing zone to the base zone. The facing zone has a thickness sufficient to prevent the base zone from being visible when the product is installed.

What is claimed is: 
     
         1 . A multi-zone cementitious product comprising:
 a base zone made of a first cementitious material composition and forming a portion of the product;   at least one facing zone adjacent to and bonded to the base zone, the at least one facing zone made of a second cementitious material composition and forming at least one exterior face of the product which is visible when the product is installed;   a disrupted boundary layer between the at least one facing zone and the base zone including material from both the at least one facing zone and the base zone;   the disrupted boundary layer bonding the at least one facing zone to the base zone; and   the at least one facing zone having a thickness sufficient to prevent the base zone from being visible when the product is installed.   
     
     
         2 . The multi-zone cementitious product of  claim 1 , wherein the product is made using a dry cast process. 
     
     
         3 . The multi-zone cementitious product of  claim 1 , wherein the product is made using a wet cast process. 
     
     
         4 . The multi-zone cementitious product of  claim 1 , wherein the at least one facing zone has a texture. 
     
     
         5 . The multi-zone cementitious product of  claim 1 , further including a bonding layer having a third material composition and disposed between the base zone and the at least one facing zone. 
     
     
         6 . The multi-zone cementitious product of  claim 1  having a first and second facing zone, the first facing zone having a first facing zone cementitious material composition, the second facing zone having a second facing zone cementitious material composition. 
     
     
         7 . The multi-zone cementitious product of  claim 1  having a plurality of facing zones, each of the plurality of facing zones having a unique cementitious material composition. 
     
     
         8 . The multi-zone cementitious product of  claim 1 , wherein the product has core holes. 
     
     
         9 . The multi-zone cementitious product of  claim 1 , wherein the disrupted boundary layer is formed by vibrating and compressing the multi-zone cementitious product. 
     
     
         10 . The multi-zone cementitious product of  claim 9 , wherein the disrupted boundary layer is not parallel to the direction of vibration. 
     
     
         11 . A method for making a cementitious product comprising the steps of:
 depositing a cementitious material onto a base conveyor in a material input section of a multi-forming machine;   passing the cementitious material under a top former, thereby forming an uncured slab between the top former, the base conveyor, and at least one side conveyor; and   ejecting the uncured slab from the multi-forming machine.   
     
     
         12 . The method for making a cementitious product of  claim 11  further including the steps of:
 providing a second material input section downstream of the top former; 
 providing a second top former downstream of the second material input; 
 depositing a second cementitious material onto the uncured slab at the second material input; and 
 passing the uncured slab and second cementitious material under the second top former which forms an uncured slab having two zones; 
 cutting the slab to form an uncured cementitious product; and 
 curing the uncured multi-zone cementitious product. 
 
     
     
         13 . The method for making a cementitious product of  claim 12  further including the steps of:
 inserting core mandrels onto the uncured slab before depositing the second cementitious material; and 
 removing the core mandrels from the uncured slab before curing. 
 
     
     
         14 . The method for making a cementitious product of  claim 13  further including the steps of:
 forming furrows in the uncured slab for receiving the core mandrels. 
 
     
     
         15 . The method for making a cementitious product of  claim 11  further including the steps of:
 adding a texture to one or more faces of the cementitious product before curing. 
 
     
     
         16 . The method for making a cementitious product of  claim 12  further including the steps of:
 disrupting an exposed surface of the uncured slab before depositing the second cementitious material. 
 
     
     
         17 . The method for making a cementitious product of  claim 11  further including the steps of:
 transferring the uncured slab to a coining chamber; and 
 densifying the uncured slab in the coining chamber. 
 
     
     
         18 . The method for making a cementitious product of  claim 12  further including the steps of:
 applying pressure from the first and second top former to densify the uncured slab before it is ejected from the multi-forming machine. 
 
     
     
         19 . The method for making a cementitious product of  claim 11  further including the steps of:
 applying vibration to the uncured slab before it is ejected from the multi-forming machine. 
 
     
     
         20 . A method for making a multi-zone cementitious product comprising the steps of:
 preparing a first cementitious material;   preparing a second cementitious material;   providing a molding machine including a mold with at least one mold cavity, a first and second hopper, and at least one feed carriage;   the at least one feed carriage having a plurality of feed cavities;   filling first hopper with the first cementitious material;   filling second hopper with second cementitious material;   transferring first cementitious material from the first hopper into at least one of the plurality of feed cavities;   transferring second cementitious material from the second hopper into at least one of the plurality of cavities;   inserting a transfer plate under the mold;   moving the feed carriage over the mold;   inserting at least one zone separator into the mold cavity;   depositing the first and second materials into the mold cavity, the materials separated by the at least one zone separator;   removing the at least one zone separator from the mold cavity;   returning the feed carriage to a position under the first and second hoppers;   applying a forming force to the mold to form an uncured multi-zone cementitious product;   ejecting the uncured multi-zone cementitious product from the mold onto the transfer plate; and   curing the uncured multi-zone cementitious product.